125 200 hp 90-160 kw

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Before installation or starting the compressor for the
first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of the duties
to be performed while operating and maintaining the
unit.
RETAIN THIS MANUAL WITH UNIT.
This Technical manual contains IMPORTANT SAFETY
DATA and should be kept with the air compressor at
all times.
125-200 HP/90-160 KW
SINGLE STAGE
AND
100-200 HP/75-160 KW
TWO STAGE UNITS
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
FORM: APDD 738B
November 2002
More Than Air. Answers.
Online answers: http://www.air.irco.com
Phone: 1-800-526-3615
CCN: 80440415 REV: B

AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material
and workmanship for a period of twelve months (see extended airend warranty) from the date of placing the Equipment
in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, whichever
shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to
the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair
to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed
maintained and operated such Equipment in accordance with good industry practices and has complied with specific
recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others,
shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the
Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs
of labor performed by the Purchaser or others without Company’s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited
to those specifically stated within the Company’s proposal. Unless responsibility for meeting such performance warranties
are limited to specified tests, the Company’s obligation shall be to correct in the manner and for the period of time
provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in
writing of its intention to do so. Any such Equipment will be at Purchaser’s sole risk and liability.
Note that this is Ingersoll-Rand’s standard warranty. Any warranty in force at the time of purchase of the compressor or
negotiated as part of the purchase order may take precendence over this warranty.
©INGERSOLL-RAND COMPANY

1
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from:
_______________________________________________
_______________________________________________
_______________________________________________
Ingersoll-Rand Company reserves the right to make
changes or add improvements without notice and without
incurring any obligation to make such changes or add such
improvements to products sold previously.
Number of units on order: __________________________
Customer Order Number: __________________________
Ingersoll-Rand Company Order Number: ______________
For ready reference, record the serial number and
model number of your unit here:
Serial Number: ___________________________________
Model Number:___________________________________

2
TABLE OF CONTENTS
0.0 SAFETY AND WARNINGS
0.1 safety instructions
0.2 safety precautions
0.3 decals
1.0 RECEIPT OF EQUIPMENT
1.1 inspection
1.2 unpacking and handling
1.3 tools
2.0 INSTALLATION
2.1 ventilation
2.2 foundation requirements
2.3 piping
2.4 electrical installation
2.5 outdoor sheltered
3.0 INTELLISYS®
3.1 intellisys controls
3.2 display screen
3.3 current status
3.4 main menu
3.5 operator setpoints
3.6 options
3.7 sensor calibration
3.8 alarm history
3.9 warnings
3.10 alarms
4.0 SCHEDULED PREVENTATIVE MAINTENANCE
4.1 maintenance schedule
4.2 maintenance records
4.3 maintenance procedures
4.4 inlet air filter
4.5 coolant filter
4.6 coolant
4.7 separator tank scavenge screen/orifice
4.8 coolant separator element
4.9 cooler cores (cleaning)
4.10 motor lubrication
4.11 long term storage
4.12 coolant/lubricant changeout
4.13 intellisys removal
4.14 coolant hoses
4.15 fluid and vibration monitoring
4.16 coolant sampling procedure
5.0 SYSTEMS
5.1 general system information
5.2 air cooled compressors
5.3 coolant system
5.4 compressed air system
5.5 coolant/air separation system
5.6 electrical system
5.7 stepper motor inlet control
5.8 capacity control system
5.9 automatic start/stop control
5.10 remote start/sto
6.0 TROUBLESHOOTING
7.0 OPTIONS
7.1 power outage restart option
7.2 sequencer
7.3 low ambient
7.4 separator delta-p solenoid
7.5 separator delta-p sensor
7.6 high dust filter
7.7 lead/lag cycle length
7.8 schedule start/stop
7.9 remote load/unload
7.10 modbus
7.11 integral sequencing
8.0 REFERENCE DRAWINGS
8.1 electrical schematic, star delta
8.2 foundation plan, 125/150 HP, A/C - Single Stage
8.3 foundation plan, 200 HP, A/C - Single Stage
8.4 foundation plan, 125/150 HP, W/C - Single Stage
8.5 foundation plan, 200 HP, W/C - Single Stage
8.6 foundation plan, 125/150 HP, A/C - Two Stage
8.7 foundation plan, 200 HP, A/C - Two Stage
8.8 foundation plan, 125/150 HP, W/C - Two Stage
8.9 foundation plan, 200 HP, W/C - Two Stage
8.10 flow schematic, A/C - Single Stage
8.11 flow schematic, W/C-90°F (32°C) - Single Stage
8.12 flow schematic, W/C-115°F (46°C) - Single Stage
8.13 flow schematic, A/C - Two Stage
8.14 flow schematic, W/C-90°F (32°C) - Two Stage
8.15 flow schematic, W/C-115°F (46°C) - Two Stage
8.16 typical system flow diagrams
9.0 WATER QUALITY RECOMMENDATIONS
10.0 MAINTENANCE RECORD
Weight ..............................See foundation plan, Section 8.0
Cooling Air Flow.............See foundation plan, Section 8.0
Ambient Temperature Limits ..........................35°F to 115°F
...........................................................................((2°C to 46°C)
Coolant.............................Factory Filled SSR Ultra Coolant
Coolant Change ............................8000 hours or two years
............................................................whichever comes first
Coolant Capacity
125/200 HP (90-160 KW) -
Single Stage ...................................23.0 gallons (87.4 liters)
100 HP (75 KW) -
Two Stage .......................................22.0 gallons (83.3 liters)
125-200 HP (90-160 KW) -
Two Stage .....................................30.0 gallons (113.6 liters)
Discharge Temperature Limit.........................228°F (109°C)
Power Inlet Wiring .........................Recommended conduit:
............................metallic flexible Greenfield, or equivalent
Tools ..............................................U.S. standard and metric
...................................are required to perform maintenance

3
0.0 SAFETY AND WARNINGS
0.1 SAFETY INSTRUCTIONS
Before you install this air compressor you should take the
time to carefully read all the instructions contained in this
manual.
Electricity and compressed air have the potential to cause
severe personal injury or property damage.
Before installing, wiring, starting, operating or making any
adjustments, identify the components of the air
compressor using this manual as a guide.
The operator should use common sense and good
working practices while operating and maintaining this
unit. Follow all codes, pipe adequately, understand the
starting and stopping sequence. Check the safety devices
by following the procedure contained in this manual.
Maintenance should be done by qualified personnel,
adequately equipped with proper tools. Follow the
maintenance schedules as outlined in the operators
manual to ensure problem free operation after start up.
Safety instructions in the operators manual are bold-faced
for emphasis. The signal words DANGER, WARNING and
CAUTION are used to indicate hazard seriousness levels
as follows:
Danger is used to indicate the presence of
a hazard which will cause severe personal
injury, death, or substantial property
damage if the warning is ignored.
Warning is used to indicate the presence of
a hazard which can cause severe personal
injury, death, or substantial property
damage if the warning is ignored.
Caution is used to indicate the presence of
a hazard which will or can cause minor
personal injury or property damage if the
warning is ignored.
Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.
D! DANGER
! WARNING
! CAUTION
NOTICE
WARNING
COMPRESSED AIR AND ELECTRICITY
ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS
UNIT, BE SURE THE ELECTRICAL SUPPLY
HAS BEEN CUT OFF–LOCKED & TAGGED
AND THE ENTIRE COMPRESSOR SYSTEM
HAS BEEN VENTED OF ALL PRESSURE.
1. Do not remove the covers, loosen or
remove any fittings, connections or
devices when this unit is in operation. Hot
liquid and air under pressure that are
contained within this unit can cause
severe injury or death.
2. The compressor has high and
dangerous voltage in the motor starter and
control box. All installations must be in
accordance with recognized electrical
codes. Before working on the electrical
system, be sure to remove voltage from
the system by use of a manual-
disconnect-switch. A circuit breaker or
fuse safety switch must be provided in the
electrical supply line leading to the
compressor.
Those responsible for installation of this
equipment must provide suitable grounds,
maintenance clearance and lightning
arrestors for all electrical components as
stipulated in O.S.H.A. 1910.308 through
1910.329.
3. Do not operate the compressor at higher
discharge pressure than those specified
on the Compressor Nameplate or motor
overload will occur. This condition will
result in compressor motor shutdown.
4. Use only safety solvent for cleaning the
compressor and auxiliary equipment.
5. Install a manual shut off valve (isolation
type) in the discharge line. When a safety
valve is installed between the isolation
valve and the compressor, it must have
sufficient capacity to relieve the full
capacity of the compressor(s).
6. Whenever pressure is released through
the pressure relief valve, it is due to
excessive pressure in the system. The
cause for the excessive pressure should
be investigated immediately.
7. Before doing any mechanical work on
the compressor:
a.) Shut the unit down.
b.) Electrically isolate the compressor by
use of the manual disconnect switch in the
power line to the unit. Lock and tag the
switch so that it cannot be operated.
c.) Vent pressure from the compressor and
isolate the unit from any other source of
air.
8. There can be adverse effects if
compressor lubricants are allowed to enter
plant air systems.
Air line separators, properly selected and
installed, will minimize any liquid carry-
over.
The use of plastic bowls on line filters
without metal guards can be hazardous.
From a safety standpoint, metal bowls
should be used on any pressurized
system. Review of your plant air line
system is recommended.
9. When a receiver is installed, it is
recommended that occupational safety
and health standards as covered in the
Federal Register, Volume 36, number 105,
part 11, paragraph 1910.169 be adhered to
in the installation and maintenance of this
receiver.
10. Before starting the compressor, its
maintenance instructions should be
thoroughly read and understood.
11. After maintenance functions are
completed, covers and guards must be
replaced.
0.2 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE

4
WARNING
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death.
All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take
into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, it
should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between
discharge piping, system accessories and software must be assured.
For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not
recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit
the operating parameters of the system.
It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine.
WARNING
CHECK HIGH AIR TEMPERATURE
There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-set
at 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended.
The procedure is:
1. Block off the cooling air discharge.
2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge
temperature reaches the pre-set maximum discharge air temperature setting of the Intellisys. The display should
indicate “HIGH AIREND DISCH TEMP” and flash “ALARM”.
The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and with
similar future test results.
SAFETY SHUTDOWN
“Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air. Ingersoll-Rand does not approve
specialized equipment for breathing air application and assumes no responsibility or liability for compressors used for
breathing air services.”

39540174 Rev. 05
5
0.3 DECALS
This section contains representative examples of decals
which will be appearing throughout this manual and are
applied to the compressor unit. If for some reason a
decal is defaced, painted over, or parts are replaced, we
recommend that you obtain a replacement kit as listed in
the spare parts section of the Parts List Manual Form
APDD 735 for single stage and Form APDD 736 for two
stage units.
WARNING!
Hazardous voltage. Can cause
Disconnect power before servicing.
Lockout/Tagout machine.
WARNING!
Hot surface.
Can cause severe injury.
Do not touch. Allow to cool before
servicing.
WARNING!
High pressure air.
Can cause severe injury or death.
Relieve pressure before removing filter
plugs / caps, fittings or covers.
CAUTION
Improper maintenance of
coolant filter can cause
compressor damage.
Change coolant filter after first
150 hours of operation and
every 2000 hours thereafter or
when coolant is changed.
WARNING!
Moving parts.
Do not operate with covers removed.
Service only with machine blocked to
prevent turn over.
Filler Cap.
Use only
recommended coolant.
Read instruction book
before servicing.
39543921
Lift Here
*PORO OPTION
39584529
*REMOTE START-
STOP OPTION
39547708
*FOOD GRADE
COOLANT OPTION
39568803
CAUTION!
Use of incorrect coolant can cause
system contamination.
Use only SSR ULTRA COOLANT.
* FOOD GRADE COOLANT
OPTION 39568464
* FOOD GRADE COOLANT
OPTION ONLY
*ITEMS MARKED WITH * ARE OPTIONS THAT
ARE AVAILABLE
2 REQUIRED - BASE
VIEWED
FROM
FRONT
39541362 Rev. 04 39540240 Rev. 04
39544143 Rev. 03
39540224 Rev. 04
39543921 Rev. 03 39540265 Rev. 05
39540273 Rev. 04
39878657 Rev. 03

0.3 DECALS (continued)
6
WARNING!
Hot surface.
Do not touch. Allow to cool before
servicing.
Water out.
Water in.
Lift Here
Condensate
drain.
Air
Discharge
Electrical
power inlet.
DANGER!
Discharge air.
Can contain carbon monoxide or
other contaminants. Will cause
Do not breathe this air.
WARNING!
Moving parts.
Service only with machine blocked to
prevent turn over.
CAUTION!
Incorrect lifting of machine
can cause injury or property
damage.
Lift only from base channels.
Rotation.
Rotation.
39540224 Rev. 04
39540232 Rev.03
39544150 Rev. 03
39557095 Rev.05 (100-200 HP)
54425996 Rev.C (75-160KW)
39541354 Rev. 03
39540166 Rev. 06
39540257 Rev. 04
39541081 Rev. 04
39540273 Rev. 04
39541339 Rev. 03
39541321 Rev. 04
39541362 Rev. 04
39540182 Rev. 04
* WATERCOOLED UNITS ONLY
VIEWED
FROM
REAR
*
*
WARNING!
Exposed fan blade. Can cause severe
injury.
Disconnect power. Lock and tag.
39540190 Rev. 04
39857552 Rev. 04
Motors must be greased periodically.
See Operators Manual for procedure.
To obtain satisfactory compressor
operation and maintenance a minimum
of 3 feet clearance on 3 sides is
required 3-1/2 feet is required in front of
the control panel (or minimum required by
latest National Electrical code or
applicable local codes).
Refer to the Instruction / Operators
Manual before any maintenance.
Do not operate without enclosure
panels and forklift covers in place.
Enclosure panels will affect performance.
NOTICE
Compressor Package Data
COMPRESSOR MODEL...............................
CAPACITY......................................................
RATED OPERATING PRESSURE.................
MAX. DISCHARGE PRESSURE...................
MAX. MODULATE PRESSURE.....................
NOMINAL DRIVE MOTOR............................
NOMINAL FAN MOTOR................................
TOTAL PACKAGE AMPS...............................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
CONTACTOR AMP. RATING.....................................
ASSEMBLY AMP. RATING........................................
LOCKED ROTOR AMP. RATING OF ASSY. ............
AIR SOLUTIONS GROUP
DAVIDSON, NORTH CAROLINA 28036
WWW.AIR.INGERSOLL-RAND.COM 54425996 Rev.C
m3/MIN
BARG
BARG
BARG
KW
KW
CAPACITY......................................................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
AIR SOLUTIONS GROUP
WWW.AIR.INGERSOLL-RAND.COM 39557095 Rev.05
CFM
PSIG
PSIG
PSIG
H.P.
H.P.

0.3 DECALS (continued)
7
WARNING!
Only use factory supplied inlet for
incoming power. See Operators/
Instruction manual.
WARNING!
Electrical
power inlet.
VOLTAGE DECAL OPTION
INSIDE STARTER BOX
ON RIGHT SIDE
SCHEMATIC DECAL
54425996 Rev. C (75-160 KW) - 2 REQUIRED
39543764 Rev. 04
39540174 Rev. 05
39541354 Rev 03
Instruction Manual.
WARNING!
Only use factory supplied inlet for
incoming power. See Operators/
Instruction manual.
39543764 Rev. 03
Instruction Manual.
CAPACITY......................................................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
AIR SOLUTIONS GROUP
m3/MIN
BARG
BARG
BARG
KW
KW
39921804 Rev. B
NOTICE
IEC Starter Overload Setting
1. Full-Voltage Starter (Main or Fan Motor):
Multiply MOTOR nameplate amps by 1.11.
Star-Delta Starter (Main motors only):
Multiply MOTOR nameplate amps by 0.64.
2. Set corresponding overload relay at
this value.
3. Never exceed the following limits:
Full-Voltage Starter: 125% of MOTOR
nameplate amps.
Star-Delta Starter: 72% of MOTOR
nameplate amps.
39557095 Rev.05 (100-200 HP) - 2 REQUIRED
CAPACITY......................................................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
AIR SOLUTIONS GROUP
CFM
PSIG
PSIG
PSIG
H.P.
H.P.

8
1.0 RECEIPT OF EQUIPMENT
1.1 INSPECTION
When you receive the compressor please inspect it
closely. Any indication of careless handling by the carrier
should be noted on the delivery receipt especially if the
compressor will not be immediately uncrated. Obtaining
the delivery man’s signed agreement to any noted
damages will facilitate any future insurance claims.
1.2 UNPACKING AND HANDLING
The compressor package has been mounted on a base
which provides for forklifting between the two side
channels to facilitate handling during shipment. Care in
positioning the forklifts is important because the location
of the center of gravity is strongly affected by the location
of the compression module and drive motor.
Slings can be used to lift the crates, but spreader bars
must be used to prevent the slings from exerting a force
against the sides of the crates.
1.3 TOOLS
Remove compressor unit from wooden skid. A crowbar
and hammer will be needed.
IMPORTANT
READ THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENT
IMMEDIATELY UPON ARRIVAL
OUR RESPONSIBILITY FOR THIS SHIPMENT
CEASED WHEN THE CARRIER SIGNED
BILL OF LADING
If goods are received short or in damaged condition, it is important that
you notify the carrier and insist on a notation of the loss or damage
across the face of the freight bill. Otherwise no claim can be enforced
against the transportation company.
If concealed loss or damage is discovered, notify your carrier at once
and request an inspection. This is absolutely necessary. Unless you do
this the carrier will not entertain any claim for loss or damage. The agent
will make an inspection and grant a concealed damage notation. If you
give the transportation company a clear receipt for goods that have been
damaged or lost in transit, you do so at your own risk and expense.
WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE
MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE
WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE
FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.
THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR
RESPONSIBILITY.
Ingersoll-Rand Company
Davidson, North Carolina
APDDGFO-99-79
Before starting this air compressor unit, the
shipping brace(s) must be removed.
Save the brace(s) for future use.
IMPORTANT
See tag in unit.
FORKLIFT PADDING
WILL REDUCE SCRATCHES
AND MARS
SPREADER
BARS

2.0 INSTALLATION
2.1 VENTILATION
Oil flooded rotary air compressors produce large
amounts of heat. Because of this large heat production,
the compressor must be placed in a room with adequate
ventilation.
If heated air from the compressor exhaust is allowed to
recirculate back to the compressor, the compressor will
overheat and shut down. This heat must be exhausted
from the room. You should take this into consideration
when you decide where to place the compressor within
your plant. Consider that the required maintenance
clearance is 3 ft (.9 m) all around the compressor.
However 42” (1.06m), or minimum required by latest NEC
or applicable local codes, must be maintained in front of
control panel.
Ambient temperatures higher than 115°F (46°C)
should be avoided as well as areas of high humidity.
Consider also the environment surrounding or near
the compressor.The area selected for the location of
the compressor should be free of dust, chemicals,
metal filings, paint fumes and overspray.
2.2 FOUNDATION REQUIREMENTS
Refer to the foundation plan for the particular model
compressor to be installed. See Section 8.0.
The compressor can be installed on any level floor that is
capable of supporting it. Compressor weights are listed
on the foundation plans.
When sound transmission is of particular importance it is
often helpful to install a sheet of rubber-fabric-matting, or
cork under the compressor to reduce the possibility of
resonant sounds being transmitted or amplified through
the floor.
2.3 PIPING
The use of plastic bowls on line filters without metal
guards can be hazardous. Their safety can be affected by
either synthetic lubricants or the additives used in mineral
oil. From a safety standpoint, metal bowls should be used
on any pressurized system. Review of your plant air line
system is recommended.
The built-in aftercooler reduces the discharge air
temperature well below the dew point (for most ambient
conditions), therefore, considerable water vapor is
condensed. To remove this condensation, each
compressor with built-in aftercooler is furnished with a
combination condensate separator/trap.
DUST CHEMICALS
METAL
FILINGS
PAINT
SPRAY
OVERSPRAY
Do not use plastic pipe, soldered copper
fittings or rubber hose for discharge piping.
WARNING
Never elevate the compressor unit
above the floor level.This may allow air
to enter the cabinet under the base.
Performance will be affected.
NOTICE
9
36”
(.9 m)
36” (.9 m)
42” (1.06m) OR
CODE MINIMUM

10
DISCHARGE PIPING WITH AFTERCOOLER
ROTARY-RECIP IN PARALLEL
Do not use the compressor
to support the discharge pipe.
Careful review of piping size from the compressor
connection point is essential. Length of pipe, size of pipe,
number and type of fittings and valves must be
considered for optimum efficiency of your compressor.
It is essential when installing a new compressor to review
the total plant air system. This is to ensure a safe and
effective total system.
Liquid water occurs naturally in air lines as a result of
compression. Moisture vapor in ambient air is
concentrated when pressurized and condenses when
cooled in downstream air piping.
Moisture in compressed air is responsible for costly
problems in almost every application that relies on
compressed air. Some common problems caused by
moisture are rusting and scaling in pipelines, clogging of
instruments, sticking of control valves, and freezing of
outdoor compressed air lines. Any of these could result in
partial or total plant shutdown.
Compressed air dryers reduce the water vapor con-
centration and prevent liquid water formation in
compressed air lines. Dryers are a necessary companion
to filters, aftercoolers, and automatic drains for improving
the productivity of compressed air systems.
NOTICE
2.3 PIPING (Continued)
A dripleg assembly and isolation valve should be
mounted near the compressor discharge. A drain line
should be connected to the condensate drain in the
base.
IMPORTANT: The drain line must slope downward from
the base to work properly.
NOTE: For ease of inspection of the automatic drain trap
operation, the drain piping should include an open funnel.
It is possible that additional condensation can occur if the
downstream piping cools the air even further and low
points in the piping systems should be provided with
driplegs and traps.
IMPORTANT: Discharge piping should be at least as
large as the discharge connection at the compressor
enclosure. All piping and fittings must be suitable for the
maximum operating temperature of the unit and, at a
minimum, rated for the same pressure as the compressor
sump tank.
MOISTURE CONTENT OF COMPRESSED AIR
200
160
120
80
40
0
DEW POINT
without
Aftercooling
100°F/38°C
(with
Aftercooler)
35°F /1.7°C
(Refrigerated
Dryer)
-40°F/-40°C
(Desiccant
Dryer)
GallonsofWater/24
hours/1000acfm

11
2.4 ELECTRICAL INSTALLATION
Before proceeding further, we recommend that you
review the safety data in the front of this manual.
Locate the compressor data plate on the side of the
cooler box or end of the unit.
The data plate lists the rated operating pressure, the
maximum discharge pressure and the electric motor
characteristics and power.
Confirm that the line voltage and compressor nameplate
voltage are the same and that the standard starter box
meets the intent of NEMA 1 guidelines.
Open the starter box door. Confirm that all electrical
connections are made and tightened. Confirm that the
control transformer is wired correctly for supply voltage.
See Figure 2.4-1 on next page for typical control
transformer wiring.
Two types of dryers, refrigerated or desiccant, are used
to correct moisture related problems in a compressed air
system. Refrigerated dryers are normally specified where
compressed air pressure dew points of 33°F (1°C) to
39°F (4°C) are adequate. Desiccant dryers are required
where pressure dew points must be below 33°F (1°C).
Contact your local Ingersoll-Rand distributor for
assistance in selecting correct Ingersoll-Rand filtration or
drying products.
NOTE: Screw type compressors should not be installed
in air systems with reciprocating compressors without a
means of pulsation isolation, such as a common receiver
tank. We recommend both types of compressor units be
piped to a common receiver utilizing individual air lines.
When two rotary units are operated in parallel, provide an
isolation valve and drain trap for each compressor before
the common receiver.
ROTARY TWO COMPRESSOR SYSTEM
PRESSURE
RELIEF
VALVE
PRESSURE
GAUGE
54425996 Rev. C (75-160 KW)
CAPACITY......................................................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
AIR SOLUTIONS GROUP
m3/MIN
BARG
BARG
BARG
KW
KW
39557095 Rev.05 (100-200 HP)
CAPACITY......................................................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
AIR SOLUTIONS GROUP
CFM
PSIG
PSIG
PSIG
H.P.
H.P.

If the compressor is operated in the
opposite direction of rotation, airend damage
can result and is not warrantable.
CAUTION
12
ELECTRICAL INSTALLATION (Continued)
Inspect the motor and control wiring for tightness.
Close and fasten the starter box door.
ROTATION CHECK
Locate the rotation decal on each motor.
DRIVE MOTOR
The correct compressor drive motor rotation is
clockwise when viewed from the rear or non-drive
end of the motor. See Figure 2.4-2.
FIGURE 2.4-2 DRIVE MOTOR ROTATION
FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING
DRIVE
END
NON-DRIVE
END
110
110
110
110V

13
ELECTRICAL INSTALLATION (Continued)
The Intellisys will automatically shut the unit down if the
compressor rotation is incorrect, and the display will
indicate “CHECK MOTOR ROTATION” and will flash
“ALARM”.
For the compressor motor rotation check, the motor
jogging time must be as short as possible.
After depressing the start button, IMMEDIATELY
depress the “EMERGENCY STOP” button. Should the
motor rotation be incorrect, put main disconnect in
the OFF position, lock and tag. See Figure 2.4-3.
Fan motor rotation is clockwise when viewed from
the fan motor side.
INTELLISYS OPERATING INSTRUCTIONS
Read and understand the following Intellisys Operating
Instructions (See Figure 2.4-4) prior to operating the unit.
NOTE: These instructions are also contained on
the decal near the Intellisys panel of the unit.
FIGURE 2.4-3 MAIN DISCONNECT
LOCKED AND TAGGED
Open the starter box door.
Interchange any two line connections (L1, L2 or L3) at
the starter. Close and fasten the starter box door.
Recheck for correct rotation.
FAN MOTOR
Observe the compressor cooling fan. The rotation should
be in accordance with the fan rotation decal affixed to the
fan motor. Cooling air should exhaust through fan end of
compressor enclosure.
Should the motor rotation not be correct, put the main
disconnect in the OFF position, lock and tag.
Interchange any two fan motor leads at the fan motor
manual starter (MMS). Close and fasten the starter box
door. Recheck for correct rotation.
HASP
KEY
LOCK
LEVER
TAG
FIGURE 2.4-4 INTELLISYS
OPERATING INSTRUCTIONS

14
2.5 OUTDOOR SHELTERED INSTALLATION
Many times a compressor must be installed outside due
to jobsite conditions or limited space within a
manufacturing facility. When this occurs there are certain
items that should be incorporated into the installation to
help ensure trouble free operation. These items have
been listed below plus Figure 2.5-1 has been included to
show a typical outdoor sheltered installation. The unit
must be purchased with the Outdoor Modification Option
to provide NEMA 4 electrics and a cabinet exhaust on
the end of the unit rather than the top to prevent recir-
culation of cooling air.
s The compressor should be on a concrete pad
designed to drain water away. If the concrete pad is
sloped, then the compressor must be leveled. In order
to properly pull cooling air through the aftercooler, the
base/skid must be sealed to the concrete pad.
s The roof of the shelter should extend a minimum of
4 ft (1.2 m) around all sides of the compressor to pre-
vent direct rain and snow from falling on the unit.
s Air-cooled machines must be arranged under the
shelter in a way that prevents air recirculation (i.e. hot
exhaust back to the package inlet).
s If the installation includes more than one compressor,
the hot air exhaust should not be directed towards the
fresh air intake of the second unit or an Air Dryer.
s If a standard machine is to be installed outside, the
ambient temperature must never drop below 35°F
(1.7°C).
s If ambient temperature drops below 35°F (1.7°C) to as
low as –10°F (–23°C) the unit must be supplied with
the Low Ambient Option. Installations below –10°F
(–23°C) ambient are not recommended. The Low
Ambient Option requires a separate power source to
operate internal heaters.
s Arrange the machine with the Intellisys con-
troller/starter enclosure facing away from the sun as
radiant heat can affect starter/lntellisys performance.
Also direct sunlight and UV rays will degrade the
membrane touch panel. This is not a warrantable
situation.
s Power disconnect switch should be within line of sight
and in close proximity to the unit. N.E.C. and local
electrical codes must be followed when installing the
power disconnect switch.
s Condensate drains must never be allowed to dump on
the ground. Run to a suitable sump for future
collection and disposal or separation of lubricant and
water mixture.
s Incoming power connections must use suitable
connectors for outdoor weather tight service.
s A minimum of 3 ft (.9 m) clearance must be allowed
on all four sides of the unit for service access. If
possible, access by a forklift and/or an overhead beam
hoist should be kept in mind (for eventual service to
airend or motor).
s If the area around the installation contains fine
airborne dust or lint and fibers etc., then the unit
should be purchased with the High Dust Filter Option
and TEFC motors.
s If larger debris, such as leaves or trash, are blowing in
the area, the Inlet Panel Filter Accessory should be
purchased and added to the unit (ship loose item).
s Some type of protection such as a fence or security
system, should be provided to prevent unauthorized
access.

FIGURE 2.5-1 TYPICAL OUTDOOR SHELTERED INSTALLATION
15

16
3.0INTELLISYS
INTELLISYS CONTROLLER
INGERSOLLrAND
INTELLISYS

3.0 INTELLISYS
3.1 INTELLISYS CONTROLS
EMERGENCY STOP
Pressing this switch stops the compressor immediately.
The compressor can not be restarted until the switch is
manually reset. Turn the switch knob clockwise to
reset.
POWER ON LIGHT
This indicates the control voltage and the line voltage
are available for starting.
The operator panel is divided into two areas. The
bottom row of four buttons provides direct control over
the starting, stopping, unloading and loading of the
compressor. These are defined by the symbols printed
on the buttons themselves, as shown here.
START
Pressing this button will start the compressor if the
display shows “Ready To Start”. The compressor will
start and load if there is sufficient demand for air.
STOP
Pressing this button will activate the unloaded stop
sequence. If the compressor is running loaded, it will
unload and continue to run unloaded for an adjustable
10 to 30 seconds and then stop. If the compressor is
running unloaded, it will stop immediately.
UNLOAD
Pressing this button will cause the compressor to
unload and remain unloaded. The display will indicate
the machine is “Running Unloaded”, and “Mode:
UNLOAD”.
LOAD
Pressing this button will cause the compressor to load
if the compressor is running and if the “Discharge
Pressure” is less than the “Online Pressure”. This also
returns the machine to the operating mode that is
specified by the “Mode of Operation” set point.
The other five buttons provide access to various
operator-selectable functions and machine operating
conditions. The purpose of each of these buttons is
defined by the display screen and the particular
function being performed at that time.
ARROWS
These up and down buttons have multiple functions
relating to the right half of the display screen. When
lists are presented, the buttons are used to move up or
down through the items on the list. The small arrow(s)
displayed in the upper right corner of the display
screen indicate when you can move up (designated by
arrow head pointing up) and/or down (designated by
arrow head pointing down) through the list.
When the value of a specific machine operating
parameter is highlighted on the display screen for the
purpose of changing that value, the buttons are used
to change the value itself.
DISPLAY BUTTONS
The functions of the three buttons below the display
screen change and are defined by the words
immediately above them in the bottom line of the
screen. Each function, such as MAIN MENU, STATUS,
SET, etc., is described in appropriate sections in this
manual.
EMEG
STOP
POWER
ON
17

The display screen is divided into three functional
areas, as seen in the typical CURRENT STATUS
screen shown here.
The left side continuously shows the package
discharge pressure in large numbers, with the line
directly below the numbers showing the running
condition of the machine, and the line below that
showing the present mode of operation.
The right side shows various items or lists such as the
machine’s CURRENT STATUS readings, the MAIN
MENU, the OPERATOR SETPOINTS list, etc. Any of
the lists can be moved up or down by pressing the
arrow buttons to the right of the screen. The small
arrow(s) displayed in the upper right corner of the
screen indicate when you can move up (designated by
arrow head pointing up) and/or down (designated by
arrow head pointing down) through a list. The arrow
buttons are also used to change an individual item’s
value. At certain times, items and/or their values are
“highlighted”. This means they are displayed as light
characters on a dark background.
The bottom of the screen is divided into thirds with the
words in each small box showing the function of the
button directly beneath it. The words will change in
these boxes depending on what actions are permitted
at any particular time. The action resulting from
pressing each of these buttons is indicated in Figure
3.2.1, which can be used as a quick reference of how
to step the controller screen through any desired
function.
1 0 0 P S I
3.2 DISPLAY SCREEN
3.3 CURRENT STATUS
The CURRENT STATUS screen is considered the
“normal” display that the controller shows.
The following items and their present values can be
displayed on the right side of the screen by pressing
the up and down arrow buttons.
CURRENT STATUS Items
Discharge Temperature Inlet Vacuum
Airend Discharge Temperature Inlet Filter
Injected Temperature Total Hours
Sump Pressure Loaded Hours
Separator Pressure Drop % Load Modulation
Unloaded Inlet Vacuum
Coolant Pressure
Time & Date
Coolant Filter Software Title
and Version
The controller automatically returns the display to this
CURRENT STATUS screen from other screens if no
buttons are pressed within 30 seconds.
The MAIN MENU screen can be accessed from the
CURRENT STATUS screen by pressing the MAIN
MENU button, identified by the words “MAIN MENU” in
the bottom line of the screen directly above the center
button.
1 0 0 P S I
Running Loaded
Mode: MOD/ACS
- CURRENT STATUS-
Package Discharge Temp
103°F
Airend Discharge Temp
193°F
MAIN MENU
Running Loaded
Mode: MOD/ACS
-CURRENT STATUS-
103°F
193°F
MAIN MENU
18

19
NOTE - Use the UP and DOWN arrows to move between selections. Items will be highlighted in inverse display mode.
* - Selecting the highlighted item will display the corresponding menu.
** - Selecting the highlighted item will place the value in edit mode. This is indicated by only the value being displayed in inverse display mode.
*** - The UP and DOWN arrows will alter the value. Depressing “Cancel” will exit the edit mode and leave the value unchanged. Depressing
“Set” will save the new value and flash the value to indicate acceptance.
**** - Depressing “Cancel” will exit calibration mode. Depressing “Calibrate” will calibrate selected sensor.
***** - Use UP and DOWN arrows to scroll through list of status items.
INTELLISYS
OperatorPanelFlowDiagram
Figure3.2.1
CURRENT STATUS
MAIN MENU*
OPERATOR
SETPOINTS**
OPTIONS**
SENSOR
CALIBRATION**
ALARM
HISTORY**
OPERATOR
SETPOINTS
ITEM***
OPTIONS
ITEM***
SENSOR
CALIBRATION
ITEM****
ALARM
HISTORY
ITEM*****
“Main Menu”
“Select” “Select” “Select” “Select”
“Main Menu”“Main Menu”
“Main Menu”
“Main Menu” “Main Menu”
“Main Menu”
“Status”“Status” “Status”
“Status”
“Status”
“Status”
“Status”
“Select”
“Cancel” or “Set” “Cancel” or “Set” “Cancel” or “Set”“Cancel” or “Calibrate”
CLOCK
FUNCTIONS
DATE AND
TIME
“Select”
“Main Menu”
“Main Menu”
“Status”
“Status”
“Cancel” or “set”
INTEGRAL
SEQUENCING
INTEGRAL
SEQUENCING
ITEM***
“Select”
“Main Menu”
“Main Menu”
“Status”
“Status”
“Cancel” or “set”“Alarm Hist.” “Cancel ot Set” “Cancel ot Set”

1 0 0 P S I
3.4 MAIN MENU
The MAIN MENU screen is the point from which
various operator functions can be accessed. Refer to
the reference diagram in Figure 3.2.1.
Each of the functions can be chosen by using the up
and down arrows to highlight it on the screen.
The controller will go to the highlighted function if the
SELECT button is pressed or will return to the
CURRENT STATUS screen if the STATUS button is
pressed.
STATUS SELECT
Ready To Start
-MAIN MENU-
Operator Setpoints
Options
Sensor Calibration
Alarm History
Clock Functions
1 0 0 P S I
3.5 OPERATOR SETPOINTS
STATUS MAIN MENU SELECT
Ready To Start
-OPERATOR SETPOINTS-
Offline Pressure
103 PSI
Online Pressure
93 PSI
Setpoints are user-adjustable variables in the
controller logic that can be set using the OPERATOR
SETPOINTS screen.
The name and value of each of the setpoints listed
below can be seen on the screen by moving the list up
and down using the arrow buttons.
Setpoints associated with options are described in the
OPTIONS Section 3.6.
A setpoint’s value can be changed by first highlighting
the item and its value and pressing the SELECT
button to highlight just the value. When the value line is
highlighted by itself, the value can be adjusted using
the up and down arrow buttons. The CANCEL and
SET buttons appear at this time. Press the SET button
to enter the new value, or press the CANCEL button to
return to the value of the setpoint prior to using the
arrows. The displayed value will flash twice to indicate
it has been entered into the setpoint, and the pair of
setpoint item and value display lines will again be
highlighted together.
Operator set points can be exited by pressing the
STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to
the CURRENT STATUS screen.
OPERATOR SETPOINTS RANGE STEP UNIT
Lead/Lag Lead or Lag --- ---
Offline Pressure 75 to RATED +3 1 PSIG
Online Pressure 65 to OFFLINE - 10 1 PSIG
Lag Offset 0 to 45 1 PSIG
Mode of Operation MOD/ACS, ON/OFF LINE, --- ---
MODULATION ONLY
Max Modulation Pressure Online + 10 to Offline + 7 1 PSIG
Stop Delay Time 10 to 60 1 SEC
Star-Delta Time* 5 to 20 1 SEC
(Screen) Contrast 0 to 10 1 ---
* Does not apply to automatic across the line starters.
20

3.5.1 Lead/Lag- This setpoint is used for setting lead
or lag operation. If set to lead, the controller will load
and unload the compressor by the online and offline
setpoints. If set to lag, the controller will subtract the
lag offset (see 3.5.4) from the online and offline set
points and operate the compressor at the lower
pressure range.
3.5.2 Offline Pressure- This setpoint is the pressure
the compressor will unload at if it is operating in on/off
line mode.
3.5.3 Online Pressure- This setpoint is the pressure
the compressor will load at.
3.5.4 Lag Offset- This setpoint is used with the
lead/lag operation. If the lead/lag set point is set to lag
(see 3.5.1), the value of the lag offset will be
subtracted from the online and offline setpoints.
3.5.5 Mode of Operation- This setpoint is used to
select the operating mode of the compressor. The
choices are MOD/ACS, ON/OFF LINE, and
MODULATION ONLY. See section 5.8 for more
information on these operating modes.
3.5.6 Max Modulation Pressure- This setpoint is the
pressure the compressor will unload at if it is
modulating. As the package discharge pressure rises
toward this value, the inlet valve will start to close. The
compressor will unload once the package discharge
reaches this value. See section 5.8 for more
information on modulation.
3.5.7 Stop Delay Time- This setpoint is the minimum
amount of time the compressor will run unloaded
before stopping. This period does not apply to alarms
(shutdowns).
3.5.8 Star-Delta Time- This setpoint is only used with
star-delta starters. It is not used if the starter is full
voltage or a remote starter. This is the time period
between starting and star-delta transition.
3.5.9 Contrast- This setpoint is used to improve the
display on the Intellisys.
1 0 0 P S I
-OPTIONS-
Auto Restart
Off
Auto Restart Time
10 MINUTES
3.6 OPTIONS
Options are turned on or off and their associated
values are set using the OPTION screen.
Some options require additional machine hardware
and the proper “Option Module” to plug into the
Intellisys controller. Descriptions of the options
operations are in Section 7.0. The name and value of
each of the options listed in the right hand column can
be seen by moving the list up and down using the
arrow buttons.
An Option item’s value can be changed the same way
OPERATOR SETPOINTS values are changed. See
Section 3.5 for an explanation.
OPTIONS ITEMS RANGE STEP UNIT
Auto Restart On/Off --- ---
Auto Restart Time 2 to 60 1 MIN
Auto Restart Delay Time 0 to 60 1 SEC
Sequencer On/Off --- ---
Remote Start/Stop On/Off --- ---
Power Out Restart On/Off --- ---
Power Out Restart Time 10 to 600 1 SEC
Low Ambient On/Off --- ---
Min. Cooler Out Temp 30 to 150 1 Deg. F
Separator Delta-P Solenoid On/Off --- ---
Separator Delta-P Sensor On/Off --- ---
Lead/Lag Cycle Length 0-750 1 HRS
Scheduled Start 00:00 to 23:59 1 TIME
Scheduled Stop 00:00 to 23:59 1 TIME
High Dust Filter On/Off --- ---
Modbus Protocol On/Off/ICU --- ---
Modbus Address 1 to 247 1 ---
Ready To Start
21

22
3.6.1 Auto Restart- This setpoint is used to enable or
disable the auto restart option.
3.6.2 Auto Restart Time- This setpoint is the minimum
time period the compressor must run unloaded before
it can stop in the auto restart mode.
3.6.3 Auto Restart Delay Time- If the compressor is
stopped in auto restart, this setpoint is the number of
seconds the package discharge pressure must remain
below the online pressure setpoint before the
compressor will restart.
3.6.4 Sequencer- This setpoint is used to enable or
disable sequencer operation.
3.6.5 Remote Start/Stpop- This setpoint is used to
enable or disable the remote start/stop option.
3.6.6 Power Out Restart- This setpoint is used to
enable or disable the power out restart option, if it is
installed.
3.7.7 Power Out Restart Time- If the power out
restart option is installed and enabled, this setpoint is
time period between power returning to the
compressor and the compressor starting.
3.6.8 Low Ambient- This setpoint enables or disables
the low ambient option. If the low ambient option is
enabled, sensor 3CTT must be installed in the
compressor.
3.6.9 Minimum Cooler Out Temperature- When the
low ambient option is installed, this setpoint is the
minimum temperature to which the coolant must rise
before the compressor will load.
3.6.10 Separator Delta-P Solenoid- This setpoint
enables or disables the separator delta-p solenoid
option. Enabling this option will automatically disable
the Separator Delta-P Sensor option.
3.6.11 Separator Delta-P Sensor- This setpoint
enables or disables the separator delta-p sensor
option. Enabling this option will automatically disable
the Separator Delta-P Solenoid option.
3.6.12 Lead/Lag Cycle Length- This setpoint enables
the automatic cycling between lead and lag operation.
If it is set to a value greater than 0, the controller will
cycle between lead and lag operation. The value of this
set point is the cycle length in real time hours. A value
of 0 will disable the automatic cycling between lead
and lag.
3.6.13 Scheduled Start- If the scheduled start/stop
option is installed, this set point is the time of the day
(hour and minute) that the compressor will
automatically start. To disable this option, set it to the
same value as the scheduled stop (section 3.6.14).
3.6.14 Scheduled Stop- If the scheduled start/stop
option is installed, this setpoint is the time of the day
(hour and minute) that the compressor will
automatically stop. To disable this option, set it to the
same value as the scheduled start (section 3.6.13).
3.6.15 High Dust Filter- This option enables or
disables the high dust filter operation.
3.6.16 Modbus Protocol- This option is for Ingersoll-
Rand service use only.
3.6.17 Modbus Address- This feature is used with the
Modbus Protocol and is for Ingersoll-Rand service use
only.
3.6 OPTIONS (CONTINUED)

3.7 SENSOR CALIBRATION
1 0 0 P S I
-SENSOR CALIBRATION-
Sensor 1AVPT
CALIBRATE
Sensor 3APT
CALIBRATE
Ready To Start
Pressure sensor calibration is done through the
SENSOR CALIBRATION screen. Sensor calibration
can only take place when the machine is stopped.
Calibration needs to be done only after a sensor has
been replaced or the Intellisys controller has been
replaced.
Each of the sensors listed below can be chosen by
using the up and down arrow buttons to highlight it on
the screen.
SENSOR CALIBRATION Items
Sensor 1AVPT
Sensor 3APT
Sensor 4APT
Sensor 5CPT
Sensor 6APT
Select the highlighted sensor by pressing the SELECT
button. Press the CALIBRATE button to start the
automatic calibration procedure, or press the CANCEL
button to not calibrate it and return to the sensor list.
The calibration screen can be exited by pressing either
the STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to
the CURRENT STATUS screen.
0
23
1 0 0 P S I
-ALARM HISTORY-
Alarm History 1
MOTOR OVERLOAD
Alarm History 2
HIGH AIREND DISCH TEMP
3.8 ALARM HISTORY
Ready To Start
Alarm History displays each of the Alarm messages
for the last 15 Alarms experienced by the machine. It
also gives access to displaying the machine operating
conditions that existed at the time of each Alarm. The
first one shown, “Alarm History 1”, was the most
recent Alarm to occur. Note that multiple, consecutive
EMERGENCY STOP Alarms are not recorded as
separate Alarms, only the first one will be shown.
Each of the last 15 Alarm messages can be seen by
moving the Alarm History list up and down using the
arrow buttons. Pressing the SELECT button when one
of the Alarms is highlighted will display the list of
machine values that existed at the time that particular
Alarm occurred.

24
1 0 0 P S I
-ALARM HISTORY 1-
Package Disch Pressure
199 PSI
103°F
STATUS MAIN MENU ALARM HISTORY
Ready To Start
The name and value of each of the items listed below
can be seen by moving the list up and down using the
arrow buttons. Pressing the ALARM HIST. button will
return the display to the ALARM HISTORY screen.
ALARM HISTORY Items
Discharge Pressure Coolant Filter
Discharge Temperature Inlet Vacuum
Airend Discharge Temperature Inlet Filter
Injected Temperature Total Hours
Sump Pressure Loaded Hours
Separator Press. Drop % Load Modulation
Unloaded Inlet Vacuum
Coolant Pressure
Time & Date
Alarm histories can be exited by pressing either the
STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to the
CURRENT STATUS screen.
1 0 0 P S I
-CLOCK FUNCTIONS-
Time
01:15
Date
Jan 01, 00
3.9 CLOCK FUNCTIONS
The date and time for the real time clock is set through
the CLOCK FUNCTIONS screen. Use the up and
down arrows to highlight either TIME or DATE. Select
the highlighted setting by pressing SELECT.
If TIME is selected, first the hours will be highlighted.
Adjust the hours (00-23 hour clock) by using the up
and down arrows. Once the correct time is in the
display, press SET to highlight the minutes. Adjust the
minutes (00-59) and then press SET to complete
setting the time.
If DATE is selected, first the month will be highlighted.
Adjust the month by using the up and down arrows
and then press SET to highlight the date. Once the
correct date is displayed, press SET to highlight the
year. Once the correct year is displayed, press SET to
complete setting the date.
Ready To Start

25
1 0 0 P S I
-INTEGRAL SEQUENCING-
Lead Compressor
Off
Total Compressors
2
3.10 INTEGRAL SEQUENCING
Integral Sequencing is set up using the INTEGRAL
SEQUENCING screen. A description of integral is in
section 7.0. The name and value of each of the
integral sequencing setpoints as listed in the right
hand column can be seen by moving the list up and
down using the arrow buttons.
3.10.1 Lead Compressor- The choices for this
setpoint are On, Off, Always, and Never. On, means
the compressor is the lead unit. Off, means the
compressor is not the lead unit, but it could become
the lead unit. If Always is selected, the compressor is
the lead unit and it will not transfer the lead to another
compressor. Never, means the compressor is not the
lead unit and will never become the lead unit. The
operator must set one unit (and only one) to On or
Always to start integral sequencing.
3.10.2 Total Compressors- This is the total number of
compressors in the integral sequence. This setpoint
must be set to the same number on each compressor.
3.10.3 Compressor Address- This is the address of
the compressor in the integral sequence. No two
compressors can have the same address. Two
compressors with the same address will cause
communication failures.
3.10.4 Load Delay Time- This is the number of
seconds the lead compressor will wait for the package
discharge pressure to start rising after issuing a load
command to another compressor. If the package
discharge pressure has not started rising at the end of
this time period, the lead compressor will load the next
compressor in the sequencer.
3.10.5 Lead Change - Hours- This is the number of
hours the compressor will operate as the lead unit.
Once a compressor has operated as the lead for this
number of hours, it will transfer the lead to the next
compressor in the sequence. This setpoint does not
apply to a unit where the lead compressor is set to
always or never. If this setpoint is set to 0, the next 2
setpoints will determine when the lead is transferred.
3.10.6 Lead Change - Day & Lead Change - Time-
These two setpoints are used together. If the Lead
Change - Hours setpoint is set to 0, these two
setpoints will be used to determine when the
compressor will transfer the lead to the next
compressor in sequence. Lead Change - Day is the
day of the week that the compressor will transfer the
lead. Lead Change - Time is the time of the day that
the compressor will transfer the lead.
Ready To Start
INTEGRAL SEQUENCING RANGE STEP UNIT
Lead Compressor On/Off/Always/Never --- ---
Total Compressors 2 to 4 1 ---
Compressor Address 1 to Total Compressors 1 ---
Load Delay Time 10 to 60 1 SEC
Lead Change - Hours 0 to 750 1 HRS
Lead Change - Day Sun to Sat, Daily, Week 1 DAY
Day, Week End
Lead Change - Time 00:00 to 23:59 1 TIME

1 0 0 P S I Change Inlet Filter
Press RESET Twice
3.11 WARNINGS
STATUS MAIN MENU RESET
Running Unloaded
Mode: MOD/ACS
1 0 0 P S I
-CURRENT STATUS-
103°F
193°F
WARNING MAIN MENU
Running Unloaded
Mode: MOD/ACS
Pressing the WARNING button will return the display
to the WARNING screen and the RESET button.
A Warning needs to be reset by the operator by
pressing the RESET button twice.
The possible Warning messages are as follows.
AIREND DISCHARGE TEMP- This will occur if the
Airend Discharge (2ATT) exceeds 97% of the alarm
limit, 228°F (109°C), and is not adjustable.
CHANGE COOLANT FILTER- This warning will occur
if the high side pressure is 20 psig (1.4 bar) greater
than the low side pressure of 1 DPS, and the Injected
Coolant temperature (2CTT) is greater than
120°F (49°C).
CHANGE INLET FILTER- This will occur if the Inlet
Vacuum (1AVPT) is greater than 0.7 psig (.05 bar) and
the machine is fully loaded (inlet valve is completely
open).
CHANGE SEPR ELEMENT- This warning will occur if
the pressure on the Separator (3APT) is 12 psig
(.8 bar) greater than the pressure at the Package
Discharge (4APT), and the machine is fully loaded.
When a Warning occurs, a question mark will flash on
the display screen and appear in large letters as
shown above. The display message will indicate what
caused the warning.
If multiple Warnings exist, the small up/down arrows
will appear in the upper right corner of the display
screen. The multiple Warnings can be seen by
pressing the up and down arrow buttons. Pressing the
STATUS button will display the CURRENT STATUS
screen with the WARNING button indicating a Warning
still exists.
?
HIGH DISCHARGE PRESS- This can occur if the
machine’s loading function is being controlled by a host
device, such as a sequencer or an lSC. This warning
will occur when the package discharge pressure is
above the maximum offline pressure (rated pressure
plus 3 psig [.2 bar]) for more than 3 seconds. This
warning will cause the compressor to unload. The host
device will not be able to load the compressor until the
package discharge pressure falls to the rated pressure
of the machine.
SENSOR FAILURE 4ATT- This will occur if the
Package Discharge Temperature Sensor (4ATT) is
recognized as missing or broken.
AUXILIARY 1 (OR 2) - This warning will occur if either
of the auxiliary contacts closes.
HIGH SUMP/LINE DIF - This warning will occur if the
compressor is running loaded, the injected coolant
temperature is greater than or equal to 120 deg. F,
(49°C) the package discharge pressure is greater than
90 psig, (6.3 bar) the sump pressure is greater than the
compressor’s rated pressure, and the sump pressure is
25 psig (1.8 bar) or more above the package discharge
pressure.
26

1 0 0 P S I High Airend Disch Temp
229°F
Press RESET Twice
3.12 ALARMS
STATUS MAIN MENU RESET
STOPPED BY ALARM
Mode: MOD/ACS
1 0 0 P S I
-ALARM STATUS-
Package Disch Pressure
100 PSI
103°F
ALARM MAIN MENU
STOPPED BY ALARM
Mode: MOD/ACS
The name and value of each of the items listed can be
seen by moving the list up and down using the arrow
buttons. Pressing the ALARM button will return the
display to the Alarm screen and the RESET button.
The Alarm needs to be reset by the operator by
pressing the RESET button twice. Any exceptions to
this are explained in the alarm descriptions.
When an Alarm occurs, an exclamation mark will flash
on the display screen as shown above. The display
message will indicate what caused the Alarm.
Pressing the STATUS button will display the ALARM
STATUS screen with the ALARM button indicating an
Alarm still exists. Alarm Status is the list of machine
operating conditions that existed at the time of the
Alarm.
COMMUNICATION FAIL 1 (or 2 - 4) - This warning
will occur if the compressor is the lead unit while using
integral sequencing and is unable to communicate with
another compressor.
SERVICED REQUIRED - The Intellisys has 2 levels of
service. The service level can be set at the factory or
by an Ingersoll-Rand service representative. Either
service level will issue a “SERVICE REQUIRED”
warning at 150 hours. This warning is a reminder for
initial service and can be cleared by the operator.
Level 1 - If service level 1 (default) is selected, a
“SERVICE REQUIRED” warning will be issued every
2000 operating hours. This warning is to serve as a
reminder to have the unit serviced and can be cleared
by the operator.
Level 2 - If service level 2 is selected, service
warnings will be issued every 2000 operating hours
(default) or in 3, 6, 9, or 12 month intervals, as
selected at the factory or by an I-R service
representative. Service warnings at level 2 are issued
in 3 stages. First a “100 HOURS TO SERVICE” or 14
DAYS TO SERVICE” (depending on the service
interval type) warning will be issued. This warning will
let the operator know that the time for service is
approaching and can be cleared by the operator.
Following that, 100 hours or 14 days later a “SERVICE
REQUIRED” warning will be issued. This warning can
be temporarily cleared by the operator, however it will
return 24 hours later if service has not been performed
by an I-R service representative. A new service period
will start when service is performed. If another 100
hours or 14 days elapses and service has not been
performed, an “ALARM-SERVICE REQUIRED”
warning will be issued. This warning can only be
cleared by an I-R service representative.
SENSOR FAILURE 6APT - This warning will occur if
the separator delta-p sensor option is installed and
sensor 6APT is recognized as missing or broken.
27
3.11 WARNINGS (CONTINUED)

28
The possible Alarm messages are as follows.
CHECK INLET CONTROL- This will occur if the
machine is unloaded and the inlet vacuum is less than
3 psig (.2 bar).
CHECK INLET CTRL SYS 1 (2) - This will occur if the
inlet butterfly valve fails to open or close properly. A 1
means the inlet valve failed to closer properly. A 2
means the inlet valve failed to open properly.
CHECK MOTOR ROTATION- This will occur if the
machine is started and the compressor has incorrect
rotation.
CONTROL POWER LOSS- This will occur if the
controller detects a loss of the 110 VAC or 120 VAC
control power.
EMERGENCY STOP- This will occur if the Emergency
Stop button is engaged. The button must be
disengaged before the alarm can be cleared.
FAN MOTOR OVERLOAD- This will occur if a fan
motor overload is sensed.
HIGH AIREND DISCH TEMP- This will occur if the
airend discharge temperature is greater than 228°F
(109°C).
LOW SUMP AIR PRESSURE- This will occur if the
machine is running fully loaded and the sump pressure
drops below 20 psig (1.4 bar).
LOW UNLOAD SUMP PRESS- This will occur if the
machine is running unloaded and the sump pressure
is less than 15 psig (1.0 bar) for 15 seconds.
MAIN MOTOR OVERLOAD- This will occur if a drive
motor overload is sensed.
CHECK SET POINTS- This will occur if the controller
has determined some of the data stored in memory
contains unacceptable values. When this occurs, the
sensors should be calibrated and all the set points
checked. It is normal for this alarm to occur after
changing controller software.
REMOTE START FAILURE- This will occur if the
Remote Start button is pressed after the machine is
running or if the Remote Start button remains closed.
REMOTE STOP FAILURE- This will occur if the
Remote Stop button remains open and either Start
button is pressed.
SENSOR FAILURE 1AVPT (or 3APT, 4APT,
5CPT,2CTT, 2ATT, 3CTT) - This will occur if a sensor
is recognized as missing or broken. This does not
apply to sensor 4ATT.
STARTER FAULT 1SL (2SL)- This will occur if the
starter contacts open while the machine is running. It
will also occur if the machine is given the stop
command and the starter contacts do not open. 1SL
refers to the auxiliary circuit on starter contact 1M. 2SL
refers to the auxiliary circuit on starter contacts 2M
and 1S.
STEPPER LIMIT SWITCH- This will occur if both limit
switches are activated at the same time.
INVALID CALIBRATION- This will occur during the
calibration process if the sensor reads greater than
20% of scale.
LOW COOLANT PRESSURE- This will occur if the
compressor is running and the following conditions are
met. The coolant must be less than 1 psi and either
the sump pressure is greater than 10 psi or the inlet
vacuum is less than 12 psi.

4.0 SCHEDULED PREVENTATIVE MAINTENANCE
4.1 MAINTENANCE SCHEDULE
THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE
COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT
NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.
4.2 MAINTENANCE RECORDS
It is very important that you, the owner, keep accurate
and detailed records of all maintenance work you, or the
Ingersoll-Rand Distributor or Air Center perform on your
compressor. This includes but is not limited to coolant
filter, separator, inlet air filter and so forth. This
information must be kept by you, the owner, should you
require warranty service work by your Ingersoll-Rand
Distributor or Air Center. Maintenance record sheets are
located at the back of this manual.
4.3 MAINTENANCE PROCEDURES
Before starting any maintenance, be certain the following
is heeded.
1. Read Safety Instructions.
2. Use correct tools.
3. Have recommended spares on hand.
SPECIAL NOTE:
Replace separator element when the separator
differential pressure ( vv P) reaches three times the
initial pressure drop or a maximum pressure
differential of 12 psi (.8 bar) at full load or if the
Intellisys warning CHANGE SEPARATOR ELEMENT is
displayed. See Section 3.9.
Running Time Interval (whichever comes first)
Action Part or Item Hours 1 Week 1 Mo. 3 Mo. 6 Mo. Yearly 2 Years
Inspect Coolant level Weekly x
Inspect Discharge temperature (air) Weekly x
Inspect Separator element differential Weekly x
Inspect Air filter Delta P (at full load) Weekly x
Inspect Oil filter Delta P Weekly x
Replace Coolant filter* 150 x (initial change only)
Check Temperature sensor 1000 x
Replace Food grade coolant (when used) 1000 x
Inspect Hoses 1200 x
Replace Coolant filter* 2000 x (subsequent changes)
Analysis Coolant 2000 See Section 4.15 x
Analysis Vibration 2000 See Section 4.15 x
Clean Separator scavenge screen and orifice 4000 x
Clean Cooler cores** 4000 x
Replace Air filter* 4000 x
Replace Separator element* *See special note.
Replace Ultra Coolant* 8000 x
Inspect Starter contactors 8000 x
Service Drive motor lubrication See Section 4.10.
* In very clean operating environments and where inlet filter is changed at the above prescribed intervals.
In extremely dirty environments change coolant, filters, and separator elements more frequently.
** Clean cooler cores if discharge air temperature is excessive or if unit shutdown occurs on high air temperature.
29

4.4 INLET AIR FILTER
To check condition of the inlet filter, run compressor in
the LOADED mode and observe “Inlet Filter” on the
CURRENT STATUS display screen. If the display says
“Inlet Filter OK”, then no maintenance is required. If “ ? ”
is flashing on the screen and the display says “CHANGE
INLET FILTER”, then the inlet filter should be changed.
To change inlet filter elements, loosen wing nut on top of
inlet filter housing. Lift cover up and away to expose
element/s.
Carefully remove the old element/s to prevent dirt from
entering the inlet valve. Discard old element/s.
Thoroughly clean the element housing and wipe all
surfaces.
Install new element/s and inspect to ensure that they
have seated properly.
Install top of inlet filter housing.
Inspect the rubber seal on the retainer wing nut and
replace seal if required.
Tighten wing nut.
Start machine and run in the load mode to verify filter
condition.
4.5 COOLANT FILTER
To check the condition of the coolant filter, the
compressor must be running. Observe “Injected
Temperature” on the CURRENT STATUS display screen.
If the temperature is less than 120°F (49°C), continue to
run the machine. When the temperature is greater than
120°F (49°C), observe “Coolant Filter” on the screen. If
the display says “Coolant Filter OK”, then the filter does
not need service. If “ ? ” is flashing on the screen and the
display says “CHANGE COOLANT FILTER”, then the
filter should be replaced.
Use a suitable device and loosen the old element. Use
drain pan to catch any leakage during removal. Discard
old element.
Wipe the sealing surface of the filter with a clean, lint-free
rag to prevent the entry of dirt into the system.
Remove the replacement element from its protective
package. Apply a small amount of clean lubricant on the
rubber seal and install the element.
Screw element/s on until the seal makes contact with the
head of the filter assembly. Tighten approximately
one-half turn additional.
Start unit and check for leaks.
INLET AIR FILTER
125-150 HP/90-110KW REQUIRES (1) ELEMENT
200 HP/132-160 KW REQUIRES (2) ELEMENTS
100 HP/75 KW-2S REQUIRES (1) ELEMENT
125-200 HP/110-160 KW - 2S REQUIRES (2)
ELEMENTS
COOLANT FILTER
100 HP/75 KW REQUIRES (1) ELEMENT
125-200 HP/90-160 KW REQUIRES (2) ELEMENTS
VALVE
FURNISHED
ONLY ON
UNITS
EQUIPPED
WITH
LUBRICANT
PUMP
30
CAUTION
Improper maintenance of
coolant filter can cause
compressor damage.
Change coolant filter after first
150 hours of operation and
every 2000 hours thereafter or
when coolant is changed.

31
COOLANT DRAIN
4.6 COOLANT
s SSR Ultra Coolant (Standard Factory Fill)
s SSR H1-F Food Grade (Optional)
SSR Ultra Coolant is a polyglycol base coolant. Change
Ultra Coolant after every 8000 hours or every two years,
whichever comes first.
SSR Food Grade Coolant is a polyalphaolefin base
coolant. Change after every 1000 hours or every 6
months whichever comes first. Do not operate unit
beyond this 1000 hour lubricant change interval, as
lubricant degradation will occur.
Items Required
In addition to the tools normally found in any reasonably
equipped serviceman’s toolbox, the following items
should be available at the work site:
1) Suitable drain pan and container to hold lubricant
drained from unit.
2) A quantity of proper lubricant sufficient to refill the
compressor.
3) A minimum of one replacement coolant filter element
of the proper type for the unit to be worked on.
There is a coolant drain hose supplied with each
compressor. The drain hose is placed in the starter box
when shipped from the factory.
The coolant should be drained soon after the compressor
has been shut down. When the coolant is hot, drainage
will be more complete and any particles in suspension in
the coolant will be carried out with the coolant.
Hot coolant can cause severe injury. Use care when
draining separator tank.
To drain the unit, remove plug from drain valve located on
the bottom of the separator tank. Install supplied drain
hose and fitting assembly in end of drain valve and place
end of hose in a suitable pan. Open drain valve to start
drainage. After draining is complete, close valve, remove
hose and fitting assembly from valve, and store in a
suitable location for future use. Replace plug in end of
drain valve.
Do not store drain hose in starter box after it has
been used to drain the separator tank.
125-200 HP/90-160 KW - Single Stage.........23 gallons (87.4 liters)
100 HP/75 KW - 2 Stage ...............................22 gallons (83.3 liters)
125-200 HP/90-160 KW - 2 stage .................30 gallons (113.6 liters)
Coolant fill quantity
WARNING
Hot coolant can cause severe injury.
Use care when near this area.
Filler Cap.
Use only
recommended coolant.
Read instruction book
before servicing.
39543921

32
4.6 COOLANT (Continued)
After the unit is drained and a new coolant filter element
is installed, refill the system with fresh coolant. Bring the
receiver level of coolant up to the midpoint of the sight
glass. Replace the fill cap. Start the compressor and run
it for a short time. The correct coolant level is at the
midpoint of the sight glass with the unit running in the
‘UNLOADED” mode.
4.7 SEPARATOR TANK
SCAVENGE SCREEN/ORIFICE
TOOLS REQUIRED
s Open end wrench
s Pliers
PROCEDURE
The screen/orifice assemblies are similar in appearance
to a straight tubing connector and will be located
between two pieces of 1/4 inch O.D. scavenge line
tubing.
The main body is made from 1/2 inch hexagon shaped
steel and the diameter of the orifice and a direction-of-
flow arrow is stamped in flat areas of the hexagon.
A removable screen and orifice is located in the exit end
of the assembly (See Figure 4.7-1) and will require
cleaning as outlined in the Maintenance Schedule,
Section 4.1.
To remove the screen/orifice, disconnect the scavenge
line tubing from each end. Hold the center section firmly
and use a pair of pliers to gently grasp the exit end of the
assembly that seals against the scavenge line tubing.
Pull the end out of the center section while using care to
prevent damage to the screen or sealing surfaces.
Clean and inspect all parts prior to reinstallation.
When the assembly is installed, confirm the direction of
flow to be correct. Observe the small arrow stamped in
the center section and ensure the direction flow to be
from the separator tank to the airend.
FIGURE 4.7-1 SEPARATOR TANK SCAVENGE
SCREEN/ORIFICE

WARNING
125/200 HP
This machine contains high air pressure
which can cause severe injury or death
from hot oil or flying parts.
Always relieve pressure before removing caps,
plugs, covers or other parts. Blow down
pressurized air system. Close isolation valve.
See Operator’s Instruction Manual.
4.8 COOLANT SEPARATOR ELEMENT
To check condition of separator element, run
compressor in full load mode and at rated pressure and
observe “Separator Pressure Drop” on the CURRENT
STATUS display screen. If the display says “xxPSI”, then
no maintenance is required. If “ ? ” is flashing on the
screen and the display says “CHANGE SEPR
ELEMENT”, then the separator element should be
replaced.
Disconnect the scavenge tube at the airend.
Loosen the fitting that holds the scavenge tube into the
tank and withdraw the tube assembly.
Disconnect the piping from the tank cover. Tag the lines
if required.
Use a suitable wrench and remove the bolts that hold
the tank cover in position. Remove cover by lifting up
and away.
Carefully lift the separator element up and out of the
tank. Discard the faulty element.
Clean the gasket surface on both the tank and its cover.
Exercise care to prevent pieces of the old gasket from
falling down into the tank.
Check the tank to be absolutely certain that no foreign
objects such as rags or tools have been allowed to fall
into the tank. Install replacement element down into the
tank after checking the new element gaskets for
possible damage. Center the element up within the
tank.
Place the tank cover in its correct position and install
bolts. Tighten the bolts in a cross-pattern to prevent
over-tightening one side of the cover. An improperly
tightened cover will likely result in a leak.
Inspect tank scavenge screen and orifice. Clean if
necessary following instructions in Section 4.7.
Install scavenge tube down into the tank until the tube
just touches the separator element and then raise it 1/8
inch (3.2 mm). Tighten fittings.
Install the regulation lines in their original position.
Start unit, check for leaks, place in service.
100-200 HP/75-160 KW 5/8-11 UNC 150 ft-lb. (203 N-M)
Tank cover bolt torque values
RECOMMENDED BOLT TIGHTENING
CROSS PATTERN
33

34
COOLANT COOLERS
Following are instructions for removal and internal
cleaning of coolant coolers.
Coolant Cooler
s Remove panels and top cover.
s Drain the coolant. See Section 4.6.
s Remove side panels from coolant cooler box.
s Disconnect piping from coolant cooler inlet and outlet
ports.
s Plug cooler inlet and outlet ports to prevent possible
contamination.
s Remove coolant cooler holding screws from sides of
coolant cooler and remove cooler through side of
cooler shroud.
Coolant Cooler Cleaning
s It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
appropriate environmentally safe cleaning agent.
s Reassemble in reverse order.
s Make sure fan guards are replaced.
s Refill the compressor with coolant. If contamination is
suspected, replace with new coolant.
s Replace fill plug.
s Run compressor for ten minutes. Check for possible
leaks. Check coolant level.
s Replace enclosure panels.
4.9 COOLER CORES: CLEANING
Ensure the compressor is isolated from the
compressed air system by closing the isolation valve
and venting pressure from the drip leg.
Ensure the main power disconnect switch is locked
open and tagged. (See Figure 4.9-1).
TOOLS REQUIRED
s Screwdriver
s Wrench set
s Air hose equipped with approved O.S.H.A. nozzle.
On units sold outside the U.S.A. consult
local codes.
PROCEDURE
Visually check the outside of the cooler cores to be
certain that a complete outside cleaning of the cooler is
required. Frequently, dirt, dust or other foreign material,
may only need to be removed with an air hose to remedy
the problem.
When the cooler is covered with a combination of
oil, grease or other heavy substances that may
affect the unit’s cooling, then it is recommended
that the cooler cores be thoroughly cleaned on the
outside.
If it is determined that the compressor operating
temperature is higher than normal due to the internal
passages of the cooler cores being restricted with
deposits or foreign material, then the cooler should be
removed for internal cleaning.
Strong cleaners can harm
aluminum cooler parts. Follow cleaner
manufacturer’s instructions for use.
Wear appropriate safety equipment.
CAUTION
LOCKED AND TAGGED
HASP
LEVER
TAG
KEY LOCK

35
AFTERCOOLER
Following are instructions for the removal and internal
cleaning of aftercoolers.
Aftercooler
s Disconnect hose from aftercooler inlet flange.
s Disconnect tube from aftercooler outlet flange.
s Remove aftercooler holding screws from aftercooler
support and remove cooler.
Aftercooler Cleaning
s It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
appropriate environmentally safe cleaning agent.
s Reassemble in reverse order.
s Replace enclosure panels.

36
Overgreasing can be a cause of bearing and
motor failure. Make sure dirt and contaminants
are not introduced when adding grease.
CAUTION
4.10 MOTOR LUBRICATION
The induction-type squirrel cage motors have antifriction
ball or roller bearings front and rear. At periodic intervals
they require relubrication.
Relubrication Interval - 60 Hz
(or 9 months, whichever comes first)
1000 hours ......................................all TEFC drive motors
2000 hours .........all ODP drive motors and all fan motors
When regreasing, stop motor. Disconnect power; lock out
and tag. Remove outlet plugs (or spring-loaded grease
relief plugs if present). The outlet plug may not be
accessible on the fan end of some TEFC motors.
Grease should be added when the motor
is stopped and power disconnected.
CAUTION
Lubricant Amount
Motor Frame Size in3
cc oz. grams
182-215 .5 8 .4 11
254-286 1.0 16 .8 23
324-365 1.5 25 1.2 34
404-449 2.5 40 2.0 57
5000 Frame Series 1.0 16 .8 23
Relubrication amount
Procedure for relubrication
NOTICE
Motors must be greased periodically.
See Operator’s Manual for procedure.
Relubrication Interval - 50 Hz
(or 9 months, whichever comes first)
2000 hours ..................M90 - 160 KW TEFC drive motors
4000 hours...................................M75 TEFC drive motors
Improper lubrication can be a cause of motor bearing
failure. The quantity of grease added should be carefully
controlled. The smaller motors must be greased with a
lesser amount of grease than larger motors.
Lubricant Amount
Motor Frame Size in3
cc oz. grams
M75-160 As indicated on motor
nameplate
Relubrication amount

37
4.10 MOTOR LUBRICATION (Continued)
Grease relief along shaft can occur, precluding necessity
of removing this plug if inaccessible. The inlet grease gun
fittings and outlet plugs (or spring-loaded reliefs) are
located at each end of the motor housing. The drive end
reliefs protrude out the circumference of the lower portion
of the end bell near a flange bolt. The drive end outlet
plugs are located just behind the flange in the air intake
area at about the 5 or 6 o’clock position.
1) Free drain hole of any hard grease (use piece of wire
if necessary).
2) Use a hand lever type grease gun. Determine in
advance the quantity of grease delivered with each
stroke of the lever. A graduated cylinder showing
cubic centimeters (cc) may be used, or a 35mm film
canister can give a close approximation for 2 cubic
inches when filled.
3) Add the recommended volume of the recommended
lubricant. Do not expect grease to appear at the
outlet, but if it does, discontinue greasing at
once.
4) Run motor for about 30 minutes before replacing out-
let plugs or reliefs. BE SURE TO SHUT MOTOR
DOWN, DISCONNECT POWER, LOCK OUT AND
TAG, AND REPLACE THESE DRAIN FITTINGS TO
PRECLUDE LOSS OF NEW GREASE AND
ENTRANCE OF CONTAMINANTS!
Recommended Motor Grease
60 Hz motors require:
Mobilith SHC 220 (39218193)
Use the grease as indicated on a special grease
information nameplate on the motor. Use of alternative
greases can result in shortened motor life due to
incompatibility of greases. If there is not a grease
nameplate on the motor use:
Chevron Black Pearl #2 (39204292)
(Preferred)
Chevron SRI 2 (39161641)
50 Hz motors require
Esso Unirex N3 (92844729)
MOTOR BEARING MAINTENANCE
(STORED UNITS)
To ensure that complete contact is maintained between
the motor bearings and the bearing grease on units to be
placed in storage for extended intervals, the following
motor maintenance procedure should be adhered to:
1) Prior to placing a unit in storage, rotate the motor
several revolutions by hand in the proper direction of
rotation.
2) Thereafter, rotate the motor as described in Step 1 at
three month intervals until such time as the unit is
placed in service.
3) If the storage time is to exceed a total of nine (9)
months duration, the compressor must be ordered
with long term storage option.
WARNING!

38
4.11 LONG TERM STORAGE
GENERAL
The factory, upon special request, prepares compressor
units for long term storage. In such cases, a special
bulletin is supplied for storage and start-up procedures.
The bulletin provides special procedures for rotation and
lubrication of compressors during storage.
Before actual start-up of the compressor, the unit must
be drained of coolant containing vapor space inhibitors.
Procedure for long term storage start-up is covered in the
special bulletin APDD 339.
4.12 COOLANT/LUBRICANT CHANGEOUT
Ingersoll-Rand does not recommend changeout of
coolant/lubricants, however, if a coolant/lubricant
change cannot be avoided, procedure APDD 106E-87
should be obtained from your Ingersoll-Rand
representative.
4.13 INTELLISYS REMOVAL
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
open and tagged (See Figure 4.13-1).
LOCKED AND TAGGED
HASP
LEVER
TAG
KEY LOCK
Follow these precautions to minimize damage from
static electricity. Static can cause severe damage to
microcircuits.
1) Make the least possible movement to avoid build-
ing up static electricity from your clothing or tools.
2) Discharge potential static electricity by touching
(grounding) yourself to the starter box.
3) Handle circuit boards only by their edges.
4) Do not place the controller or power supply
assembly on any metal surface.
5) Leave the replacement parts in their protective
bags until ready for installation.
Tools:
Screwdriver Size #1, flathead
3/8 inch hex driver
Before removing any components, open the starter box
door and check all wiring for tightness. A loose wire or
bad connection may be the cause of problems.
This section gives guidelines for removing/replacing the
Intellisys Controller assembly and the Intellisys Power
Supply assembly. The controller is mounted in the
starter box door, and the power supply is mounted on
the upper right corner of the starter backpanel on the
inside-rear of the starter box.
Controller Removal:
1) Open the starter box door.
2) Remove each plug-in connector, labeled P1-P10,
from the sides of the controller. If any of the
cables are not labeled, label them with the
appropriate plug designator, P1-P10. These
must be plugged into the correct sockets in
the replacement controller.
3) Remove and save the Option Module if one is
plugged into P9. This must be installed in the
replacement controller. Note that it is keyed to
plug into P9 only one way.
4) Remove the six holding screws from the con-
troller on the inside of the starter box door.
5) Remove the controller through the front of the
door, being careful to save the gasket that is
between the controller and the door.

39
Power Supply Removal:
1) Open the starter box door.
2) Remove each plug-in connector, labeled J1 -
J4, from the circuit board. If any of the cables
are not labeled, label them with the appro-
priate plug designator, J1-J4. These must
be plugged into the correct sockets in the
replacement power supply.
3) Remove the four screws holding the power
supply to the starter plate, save them for
mounting the replacement board, and remove
the power supply.
4.14 COOLANT HOSES
The flexible hoses that carry coolant to and from the oil
cooler may become brittle with age and will require
replacement. Have your local Ingersoll-Rand distributor
check them every 2 years.
compressed air system by closing the isolation valve
and venting pressure from the drip leg.
open and tagged.
REMOVAL
Remove enclosure panels.
Drain coolant into a clean container. Cover the container
to prevent contamination. If the coolant is contaminated,
a new charge of coolant must be used.
Hold fitting securely while removing hose.
INSTALLATION
Install the new hoses and reassemble the package by
reversing the disassembly procedure. Start the
compressor and check for leaks.
4.15 FLUID AND VIBRATION MONITORING
Ingersoll-Rand recommends incorporating predictive
maintenance, specifically the use of coolant and vibration
analysis, into all Preventative Maintenance programs.
Predictive Maintenance is designed to increase system
reliability and prevent costly downtime. Through the use
of sophisticated diagnostic tools, including fluid, vibration,
and optional air analysis, IRA Certified Service
Technicians can identify and correct potential problems
BEFORE they can cause expensive unscheduled
downtime.
How does predictive analysis work? By establishing an
initial baseline for normal operation, and then regularly
monitoring fluid and vibration conditions, any sudden
deviation or significant increase from this baseline can be
identified and investigated to pinpoint the cause. More
quickly diagnosing potential problems can directly save
money by preventing costly failures and reducing or
eliminating downtime. In addition, regular condition
monitoring also helps to maximize the time between
expensive preventative maintenance intervals, such as
component rebuilds and coolant changes.
4.16 COOLANT SAMPLING PROCEDURE
Bring unit up to operating temperature. Draw sample,
using pump kit, from separator tank port. DO NOT draw
sample from drain port or oil filter. Use new hose on
pump for each sample, failure to do this can give false
readings.
100%
50%
OILFILTER

40
COOLING FAN MOTOR
In a standard compressor, the cooling fan motor is wired
at the factory. It is a three-phase motor, protected by a
suitable circuit breaker and overload relay. The fan motor
is energized at the same time the compressor drive
motor is energized. The fan motor overload is wired in
series with the compressor drive motor overload. If an
overload occurs in the fan motor circuit, both the fan
motor and compressor drive motor will stop.
AFTERCOOLER
The discharge air aftercooling system consists of a heat
exchanger (located at the cooling air entrance of the
machine), a condensate separator, and an automatic
drain trap.
By cooling the discharge air, much of the water vapor
naturally contained in the air is condensed and
eliminated from the downstream plant-piping and
equipment.
5.3 COOLANT SYSTEM
Coolant is forced by pressure from the receiver/separator
sump to the inlet port of the coolant cooler and the
bypass port of the thermostatic control valve.
The thermostatic control valve controls the quantity of
coolant necessary to provide a suitable compressor
injection temperature. When the compressor starts cold,
part of the coolant will bypass the cooler. As the system
temperature rises above the valve setting, the coolant will
be directed to the cooler. During periods of operation in
higher ambient temperatures, all the coolant flow will be
directed through the cooler.
The compressor injection minimum temperature is
controlled to preclude the possibility of water vapor
condensing in the receiver. By injecting coolant at a
sufficiently high temperature, temperature of the
discharge air and lubricant mixture will be kept above the
dew point.
The controlled temperature coolant passes through a
filter to the airend under constant pressure.
5.0 SYSTEMS
5.1 GENERAL SYSTEM INFORMATION
The SSR compressor is an electric motor driven, single
stage, screw compressor—complete with accessories
piped, wired and baseplate mounted. It is a totally
self-contained air compressor package.
A standard compressor is composed of the following:
s Inlet air filtration
s Compressor and motor assembly
s Pressurized coolant system with cooler
s Separation system
s Capacity control system with stepper motor inlet
s Motor starting control system
s Instrumentation
s Safety provisions
s Aftercooler
s Moisture separator and drain trap.
Optional accessories can provide for such things as
automatic starting and stopping, remote starting or
stopping, and sequencer.
The motor, airend, separator tank, and piping are
mounted on independent supports. The supports are
isolated from the base by rubber isolation mounts.
Flexible hoses are utilized on the separator tank coolant
out and air discharge to isolate the motor/airend/tank.
5.2 AIR COOLED COMPRESSORS
DESIGN TEMPERATURES
The standard compressor is designed for operation in an
ambient range of 35°F to 115°F (1.7°C to 46°C). When
conditions other than the design levels described are
encountered, we recommend you contact your nearest
Ingersoll-Rand representative for additional information.
The standard maximum temperature 115°F (46°C) is
applicable up to an elevation of 3300 ft (1000 m) above
sea level. Above this altitude, significant reductions in
ambient temperature are required if a standard drive
motor is to be used.
COOLANT COOLER
The cooler is an integral assembly of core, fan and
fan-motor, all mounted in the end section of the
compressor enclosure. The cooling air flows in through
the left end of the enclosure, through the vertically
mounted cooler core, and discharges upward through the
right end of the enclosure.

5.4 COMPRESSED AIR SYSTEM
The air system is composed of:
1) Inlet air filter
2) Inlet valve/stepper motor
3) Rotors
4) Coolant/air separator
5) Minimum pressure/check valve
6) Aftercooler
7) Moisture separator/drain trap
Air enters the compressor, passing through the inlet air
filter and butterfly inlet valve.
Compression in the screw-type air compressor is created
by the meshing of two helical rotors (male and female) on
parallel shafts, enclosed in a heavy-duty cast iron
housing, with air inlet and outlet ports located on
opposite ends. The grooves of the female rotor mesh
with, and are driven by, the male rotor. Tapered roller
bearings at the discharge end prevent axial movement of
the rotors.
The air-coolant mixture discharges from the compressor
thru a discharge check valve into the separation system.
This system, self-contained in the separator tank,
removes all but a few PPM of the coolant from the
discharge air. The coolant is returned to the system and
the air passes to the aftercooler. The aftercooling system
consists of a heat exchanger, a condensate separator,
and a drain trap. By cooling the discharge air, much of
the water vapor naturally contained in the air is
condensed and eliminated from the downstream
plant-piping and equipment.
During unloaded operation, the butterfly inlet valve
closes, via stepper motor, and the blowdown solenoid
valve opens, expelling any compressed air back to the
compressor inlet.
5.5 COOLANT/AIR SEPARATION SYSTEM
The coolant/air separation system is composed of a
separator with specially designed internals, a two-stage
coalescing-type separator-element, and provision for
return of the separated fluid back to the compressor.
Internal baffles maintain the circumferential flow of
remaining coolant droplets and air. In an almost
continuous change of direction of flow, more and more
droplets are removed from the air by inertial action and
then returned to the sump.
The air stream, now essentially a very fine mist, is
directed to the separator element.
The separator element is constructed with two
concentric, cylindrical sections of closely packed fibers,
each held in steel mesh. It is flange-mounted at the
separator-outlet-cover.
The air stream enters the separator element radially
and the mist coalesces to form droplets. The droplets
collected on the outer first stage fall to the separator
sump. Those collected on the inner second stage
collect near the outlet of the element, and are drawn
back to the compressor inlet through a filter-screen and
orifice fitting installed in the separator scavenge line.
The air stream, now essentially free of coolant, flows
from the separator to the aftercooler, then to the
condensate separator, and on to the plant air system.
5.6 ELECTRICAL SYSTEM
The electrical system of each SSR compressor is built
around the microprocessor-based Intellisys controller.
The standard electrical/electronic components,
enclosed in a readily accessible enclosure include:
1) IntelIisys controller
2) Compressor motor starter, with auxiliary contacts
and overload relays
3) Cooling fan motor overload relays and circuit
breaker or fuses
4) Intellisys Power Supply Board
5) Control transformer and fuses
Options, such as power outage restart can be enabled
by installing plug-in (option) modules in the Intellisys
controller.
OPERATION
The coolant and air discharging from the compressor
flow into the separator through a tangential discharge
outlet. This outlet directs the mixture along the inner
circumference of the separator, allowing the coolant
stream to collect and drop to the separator sump.
41

125 200 hp 90-160 kw

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125 200 hp 90-160 kw